Hybrid saw blade

ABSTRACT

A saw blade includes a blade body having a top surface and a bottom surface, wherein the blade body is at least partially comprised of a first composite material or a metal; a cutting edge on a distal end of the blade body; and a coupling configured to connect the blade body to a handpiece adapted to oscillate the blade body. The saw blade may include:a first inlay portion and a second inlay portion, where the first inlay portion is either embedded in the top surface or covers the top surface, and the second inlay portion is either embedded in the top surface or covers the bottom surface; oran inlay portion sandwiched between a top portion and a bottom portion of the blade body.

This is a Division of U.S. patent application Ser. No. 16/456,457, filedJun. 28, 2019, which in turn claims the benefit of U.S. ProvisionalApplication No. 62/692,056, filed Jun. 29, 2018. The entire disclosureof each prior application is incorporated by reference herein in itsentirety.

TECHNICAL FIELD

Various exemplary embodiments disclosed herein relate to a hybrid sawblade including a blade body that at least partially includes acomposite material.

BACKGROUND

Traditionally, oscillating saw blades, including sagittal saw blades,for surgical applications are manufactured in one piece and preferablymade from steel. The saw blades are manufactured using manufacturingmethods such as punching, laser cutting, bending, grinding, etching,stamping, etc. and have a wide variety of shapes and geometries.

Sagittal saw blades are often used for osteotomies, wherein the sagittalsaw cuts in the same plane as the body of the instrument.

Traditional saw blades are commonly characterized by having more weightwith increasing length, width and thickness, which leads to increasednoise and vibration levels, as well as to a higher mechanical load onthe transmission system, e.g., the handpiece. However, a certain lengthand thickness is indispensable for the intended use of the saw blades tobe fulfilled.

SUMMARY

A brief summary of various exemplary embodiments is presented below.Some simplifications and omissions may be made in the following summary,which is intended to highlight and introduce some aspects of the variousexemplary embodiments, but not to limit the scope of the invention.Detailed descriptions of an exemplary embodiment adequate to allow thoseof ordinary skill in the art to make and use the inventive concepts willfollow in later sections.

Various embodiments disclosed herein relate to a saw blade that includesa blade body having a top surface and a bottom surface, wherein theblade body at least partially includes a composite material, a cuttingedge on a distal end of the blade body, and a coupling on a proximal endof the blade body configured to connect the blade body to a handpieceadapted to oscillate the blade body.

Various embodiments further relate to a saw blade, wherein the saw bladefurther includes at least two of the materials selected from a groupthat includes steel, polymer, titanium and ceramic materials.

Various embodiments further relate to a saw blade, wherein at least oneof the top surface and the bottom surface of the blade body includes aninlay portion including a composite material, such as a matrix material,a plastic material, a filling material and/or a carbon fiber fabricmaterial.

Various embodiments further relate to a saw blade system, wherein thecomposite inlay portion includes a plurality of holes extending along alongitudinal axis of the blade body.

Various embodiments further relate to a saw blade system, wherein thecomposite inlay portion is surrounded by a metal frame, such as a steelframe.

Various embodiments further relate to a saw blade, wherein the bladebody and coupling both include a composite material.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to better understand various exemplary embodiments, referenceis made to the accompanying drawings, wherein:

FIG. 1 illustrates a top view of an embodiment of the saw blade;

FIGS. 2A-C illustrate a top view of embodiments of the saw blade thatinclude a blade body including a composite material;

FIG. 3 illustrates a top view of another embodiment of the saw bladewherein the blade body and coupling both include a composite material;

FIGS. 4A-F illustrate a cross-sectional view along line S in FIG. 1 ofvarious embodiments of the blade body;

FIGS. 5A-B illustrate perspective views of embodiments of the cuttingedge of the saw blade;

FIGS. 5C-E illustrate top views of other embodiments of the cutting edgeof the saw blade;

FIG. 5F illustrates a cross-sectional side view of the blade body andthe cutting edge of the saw blade;

FIG. 6A illustrates an exploded perspective view of an embodiment of thesaw blade that includes a blade body completely manufactured from acomposite material, and a cutting edge;

FIG. 6B illustrates a cross-sectional side view of the saw blade shownin FIG. 6A;

FIGS. 7A-B illustrate a perspective view and an exploded perspectiveview of another embodiment of the saw blade that includes a blade bodyincluding a composite material and a cutting edge;

FIG. 7C illustrates a cross-sectional side view of the embodiment of thesaw blade shown in FIGS. 7A-B;

FIG. 7D illustrates a perspective component view of the saw blade shaftand cutting edge of the saw blade of FIGS. 7A-7C manufactured fromdifferent materials;

FIG. 7E illustrates a perspective component view of the saw blade shaftand cutting edge of the saw blade of FIGS. 7A-7C manufactured from thesame materials;

FIGS. 8A-D illustrate top views of various embodiments of the coupling;

FIGS. 9A-D illustrate top views of various alternative embodiments ofthe blade body;

FIG. 10 illustrates a perspective view of the saw blade coupled to ahandpiece.

DETAILED DESCRIPTION

The description and drawings illustrate the principles of the invention.It will thus be appreciated that those skilled in the art will be ableto devise various arrangements that, although not explicitly describedor shown herein, embody the principles of the invention and are includedwithin its scope. Furthermore, all examples recited herein areprincipally intended expressly to be for pedagogical purposes to aid thereader in understanding the principles of the invention and the conceptscontributed by the inventor(s) to furthering the art, and are to beconstrued as being without limitation to such specifically recitedexamples and conditions. Additionally, the term, “or,” as used herein,refers to a non-exclusive or (i.e., and/or), unless otherwise indicated(e.g., “or else” or “or in the alternative”). Also, the variousembodiments described herein are not necessarily mutually exclusive, assome embodiments can be combined with one or more other embodiments toform new embodiments.

The present disclosure provides for a hybrid saw blade 100 manufacturedfrom a combination of different materials. The weight and rigidity ofthe blade body 120 of the saw blade 100 is optimized in such a way thatthe vibration and noise load on the user as well as the mechanical loadon any attached handpiece (transmission system) of an oscillating sawblade system are as low as possible without negatively affectingclinical output.

FIG. 1 illustrates an embodiment of the saw blade 100. The saw blade 100includes a coupling 110 at a proximal end 113. In this embodiment, thecoupling 110 includes a plurality of holes 111 and a U-shaped cutout 112configured to connect a blade body 120 to a handpiece 1050, shown inFIG. 10. However, the coupling 110 may be configured in any geometry,including those shown in FIGS. 8A-8D, that allows for attachment of theblade body 120 to a handpiece 1050. The blade body 120, may also beconfigured in any geometry, including those shown in FIGS. 9A-9D, thatallows for optimal weight and rigidity of the saw blade 100. Thehandpiece 1050 is adapted to oscillate the blade body 120. The saw blade100 additionally includes a cutting edge 130 at a distal end 114including a plurality of teeth 131. The blade body 120 may include aplurality of holes 121 extending longitudinally along axis X of the sawblade 100 that allows for mass reduction of the saw blade 100, andconsequent decrease in vibration, noise load, and mechanical load of thesaw blade 100.

FIG. 2A illustrates a top view of another embodiment of the saw blade100 that includes a continuous blade body 120, wherein the blade body120 includes a top surface 123 that is manufactured from a differentmaterial than the coupling 110 and the cutting edge 130.

In various embodiments, the top surface of the blade body 120 may bemanufactured from a composite hybrid material, defined as a materialmade of two or more materials bonded together under high pressure andtemperature. In various embodiments, the blade body 120 may include acarbon composite material. Suitable carbon composite materials include amatrix material, plastic, filling material, carbon fiber fabric materialor combinations thereof. In some embodiments the carbon compositematerial includes a carbon fiber fabric material or combinations ofcarbon fiber fabric materials having different strengths to achieve anoptimal stiffness of the saw blade 100. Suitable strength classes of thecarbon fiber fabric materials include high tenacity (HT), very hightenacity (UHT), low modulus (LM), intermediate modulus (IM), highmodulus (HM), ultra modulus (UM), ultra high modulus (UHM), ultramodulus strength (UMS), high modulus (HMS), and combinations thereof.

The coupling 110 and cutting edge 130 shown in FIG. 2A may bemanufactured from a metal material such as steel, titanium,titanium/ceramic material and combinations thereof. In variousembodiments, the top surface 123 may be joined to the coupling 110 andcutting edge 130 using any method known in the art used to joincomposite and metal materials to each other. Suitable methods includebonding using adhesive resins, and the like.

FIG. 2B illustrates a top view of another embodiment of the saw blade100, wherein the top surface 123 of the blade body 120 includes acomposite inlay portion 122 surrounded by a metal frame 124. In thisembodiment, the metal frame 124 protects the composite inlay portion 122from damage.

FIG. 2C illustrates a top view of another embodiment of the saw blade100, wherein the composite inlay portion 122 includes a plurality ofholes 121, that extend along a longitudinal axis of the composite inlayportion 122, for additional mass reduction.

FIG. 3 illustrates a top view of another embodiment of the saw blade100. In this embodiment, the coupling 110 is also manufactured from acomposite material.

FIG. 4A illustrates a cross-sectional view along axis S of FIG. 1 of anembodiment of the blade body 120. In this embodiment, the blade body 120includes a metal shaft 424 that includes cutouts on a top surface 123and an opposing bottom surface 125 to accommodate a first compositeinlay portion 122 positioned on the top surface 123 and a secondcomposite inlay portion 126 positioned opposite the first compositeinlay portion 122 on the bottom surface 125.

FIG. 4B illustrates a cross-sectional view along axis S of FIG. 1 of asecond embodiment of the blade body 120. In this embodiment, the bladebody 120 includes a metal shaft 424. The first composite inlay portion122 is layered on a top surface 123 of the metal shaft 424 so as tocompletely cover the top surface 123 and the second composite inlayportion 126 is layered on a bottom surface 125 of the metal shaft 124 soas to completely cover the bottom surface 125.

FIG. 4C illustrates a cross-sectional view along axis S of FIG. 1 of athird embodiment of the blade body 120. In this embodiment, the bladebody 120 includes a metal shaft 424 that includes a cutout toaccommodate a single composite inlay portion 122 on a top surface 123.

FIG. 4D illustrates a cross-sectional view along axis S of FIG. 1 of afourth embodiment of the blade body 120. In this embodiment, thecomposite inlay portion 122 is surrounded on a top surface 123, a bottomsurface 125, a first side surface 127 and a second side surface 128 by ametal shaft 424.

FIG. 4E illustrates a cross-sectional view along axis S of FIG. 1 of afifth embodiment of the blade body 120. In this embodiment, the bladebody 120 includes a metal shaft 424. The composite inlay portion 122 islayered on a top surface 123 of the metal shaft 424 so as to completelycover the top surface 123.

FIG. 4F illustrates a cross-sectional view along axis S of FIG. 1 of asixth embodiment of the blade body 120. In this embodiment, the bladebody 120 includes a metal shaft 424. The composite inlay portion 126 islayered on a bottom surface 125 of the metal shaft 424 so as tocompletely cover the bottom surface 125.

In various embodiments, the saw blade 100 has a usable length of betweenabout 70 mm to about 90 mm, a total length of about 95 mm to about 120mm and width of about 20 mm to about 25 mm. The saw blade 100 preferablyhas a thickness of about 2.00 mm. The thickness of the saw blade 100 maybe from 1 mm to 3 mm, from 1.5 mm to 2.5 mm, from 1.9 mm to 2.2 mm, orother thicknesses. The saw blade 100 is further characterized by adeflection value of about 6 mm to about 9 mm, and a mass moment ofinertia of about 50 kg*mm² to about 110 kg*mm².

In various embodiments, the saw blade 100 is configured to limit flexing(e.g. as a result of skiving) of the saw blade 100 to about 0.25 mm orless upon application of a 2.2N load, preferably 0.2 mm or less,preferably about 0.15 mm or less. In various embodiments, the saw blade100 is characterized by a weight low enough to achieve the flexing limitof 0.25 mm or less upon application of a 2.2N load, as described herein.

FIG. 5A illustrates a perspective view of an embodiment of the cuttingedge 130. The cutting edge 130 includes a plurality of teeth 131 and aconnector 132 which includes a plurality of holes 133 distributedtherethrough. During manufacture of the saw blade 100, compositematerial may be filled into the plurality of holes 133 to allow formechanical interlocking of the cutting edge 130 with the blade body 120.In another embodiment, the connector 132 may be roughened and/oractivated with primers or treated in such a way as to allow formechanical interlocking of the cutting edge 130 with the blade body 120.Suitable treatment procedures may include surface activation and/orstructuring procedures, such as plasma surface activation, UV surfacecleaning and UV surface activation, plasma etching, fluorination,etching with acid to increase surface roughness, abrasive blasting toincrease surface roughness, laser surface activation or structuring, orcombinations thereof.

FIG. 5B illustrates a perspective view of another embodiment of thecutting edge 530. The cutting edge 530 includes a plurality of teeth 531and a connector 532. The cutting edge 530 may further include aplurality of grooves 535 configured to aid in ejection of debris, e.g.bone chips, during use of the blade. The connector 532 includes aplurality of holes 533 distributed longitudinally along an axis of theconnector 532 parallel to a saw blade shaft 524. During manufacture ofthe saw blade 100, composite material may be filled in the plurality ofholes 533 to allow for mechanical interlocking of the cutting edge 530with a blade body 120. In this embodiment, the cutting edge 530additionally includes a slot 534 configured to slidably receive the sawblade shaft 524. FIGS. 5C-E illustrate other embodiments of the cuttingedge 130. Additionally, in various embodiments, as shown in FIG. 5F, thethickness of the cutting edge 130 may be greater than the thickness ofthe blade body 120.

In various embodiments, the connectors 132, 532 may have any geometrythat allows for optimal weight and rigidity of the saw blade 100. Invarious embodiments, the plurality of teeth 131,531 may further have anygeometry that allows for optimal functionality of the saw blade 100.

FIG. 6A illustrates another embodiment of a saw blade 100 that includesa blade body 120 completely manufactured from a composite material, anda cutting edge 130. The blade body 120 includes a first composite inlayportion 122, layered on a top surface 123 of a saw blade shaft 624, alsomanufactured from a composite material, so as to completely cover thetop surface 123, and a second composite inlay portion 126 layered on abottom surface 125 of the saw blade shaft 624, opposite the firstcomposite inlay portion 122, so as to completely cover the bottomsurface 125, as shown in more detail in FIG. 6B. The blade body 120,further includes a coupling hole 610 configured to couple the saw blade100 to a handpiece 1050, as shown in FIG. 10. As shown in FIG. 6A, thecutting edge 130 is merged with the saw blade shaft 624 using aconnector 132, which is received within a U-shaped cutout 140, locatedat a distal end of the saw blade shaft 624.

In various embodiments, the first composite inlay portion 122 and secondcomposite inlay portion 126 may be manufactured from the same compositematerial. In other embodiments the first composite inlay portion 122 andsecond composite inlay portion 126 may be manufactured using differentcomposite materials. In various embodiments, the saw blade shaft 624 mayalternatively be manufactured using other materials, such asunreinforced PEEK, and the like.

FIG. 7A illustrates another embodiment of a saw blade 100 that includesa coupling hole 610, a blade body 120 and a cutting edge 530. As shownin more detail in FIGS. 7B and 7C, the blade body 120 includes a firstcomposite inlay portion 122 layered on a top surface 762 of a firstintermediate composite inlay portion 760 so as to completely cover thetop surface 762 of the first intermediate composite inlay portion 760.The blade body 120 additionally includes a second composite inlayportion 126 layered on a bottom surface 763 of a second intermediatecomposite inlay portion 761, opposite the first composite inlay portion122, so as to completely cover the bottom surface 763 of the secondintermediate composite inlay portion 761. The first intermediatecomposite inlay portion 760 is layered on a top surface 123 of a sawblade shaft 724, so as to completely cover the top surface 123 of thesaw blade shaft 724. The second intermediate composite inlay portion 761is layered on a bottom surface 125 of the saw blade shaft 724, oppositethe first intermediate composite inlay portion 760, so as to completelycover the bottom surface 125 of the saw blade shaft 724. In variousembodiments, the first composite inlay portion 122, second compositeinlay portion 126, first intermediate composite inlay portion 760 andsecond intermediate composite inlay portion 761, may be manufacturedfrom the same composite material. In other embodiments, the firstcomposite inlay portion 122, second composite inlay portion 126, firstintermediate composite inlay portion 760 and second intermediatecomposite inlay portion 761 may each be manufactured from differentcomposite materials. In various embodiments, the first composite inlayportion 122, second composite inlay portion 126, first intermediatecomposite inlay portion 760 and second intermediate composite inlayportion 761 may be manufactured using composite materials of any gradethat would allow for optimal weight and rigidity of the saw blade 100.In various embodiments, the saw blade shaft 724 may be manufactured froma metallic or composite material as described herein.

In some embodiments, the first composite inlay portion 122 and secondcomposite inlay portion 126 may be manufactured using an unreinforcedPEEK material. In some embodiments, the first intermediate compositeinlay portion 760 and second intermediate composite inlay portion 761may be manufactured using a unidirectional laminate material.

As shown in FIG. 7D, the saw blade shaft 724 may be merged with thecutting edge 530 by sliding the saw blade shaft 724 into slot 534located on the connector 532. In the embodiment of FIG. 7D, the sawblade shaft 724 and cutting edge 530 may be made from the same material,e.g. stainless steel, or different materials, e.g. aluminum, titanium,ceramic, in any combination as known to a person of ordinary skill inthe art to produce a saw blade 100 of optimal weight and rigidity. Invarious embodiments, the saw blade shaft 724 and cutting edge 530 mayfurther be heat treated independently from each other to confer optimalproperties.

In various embodiments, the saw blade shaft 724 may be merged with thecutting edge 530 using any suitable merging method known to a person ofordinary skill in the art. Suitable merging methods include weldingmethods, such as laser welding, electrode beam welding, press-welding,friction welding and the like. In further embodiments, the plurality ofholes 533 located on the connector 532 may be used for welding purposeswith the saw blade shaft 724, or may be used for mechanical interlockingwith the composite layers 722, 760, 761, 726.

As shown in FIG. 7E, the saw blade shaft 724 and cutting edge 530 mayalso be manufactured as a single piece from the same material.

FIG. 10 illustrates in more detail, the saw blade 100 coupled usingcoupling hole 610 to a handpiece 1050.

Various features and structures are illustrated throughout the variousembodiments described above in specific combinations of those featuresand structures. These various features and structures may also becombined into other specific combinations not explicitly shown and stillbe within the scope of the invention disclosed herein.

Although the various exemplary embodiments have been described in detailwith particular reference to certain exemplary aspects thereof, itshould be understood that the invention is capable of other embodimentsand its details are capable of modifications in various obviousrespects. As is readily apparent to those skilled in the art, variationsand modifications can be effected while remaining within the spirit andscope of the invention. Further, various elements from the variousembodiments may be combined to form other embodiments that are withinthe spirit and scope of the invention. Accordingly, the foregoingdisclosure, description, and figures are for illustrative purposes onlyand do not in any way limit the invention, which is defined only by theclaims.

What is claimed is:
 1. A saw blade comprising a blade body having a topsurface and a bottom surface, wherein the blade body is at leastpartially comprised of a metal; a cutting edge on a distal end of theblade body; and a coupling at a proximal end of the blade bodyconfigured to connect the blade body to a handpiece adapted to oscillatethe blade body, wherein the saw blade further comprises a first inlayportion and a second inlay portion, wherein: the first inlay portion isembedded in the top surface of the blade body; the second inlay portionis embedded in the bottom surface of the blade body; and each of thefirst and the second inlay portions comprises a composite material. 2.The saw blade of claim 1, wherein the composite material is selectedfrom the group consisting of a matrix material, a plastic material, afilling material and a carbon fiber fabric material.
 3. The saw blade ofclaim 2, wherein the composite material is a carbon fiber fabricmaterial.
 4. The saw blade of claim 1, wherein the cutting edgecomprises a connector configured to mechanically interlock the cuttingedge with the blade body.
 5. The saw blade of claim 4, wherein theconnector comprises a plurality of holes configured to mechanicallyinterlock with the blade body.
 6. The saw blade of claim 1, wherein thesaw blade further comprises a plurality of holes from the top surface tothe bottom surface of the blade body, the plurality of holes beingarranged along a longitudinal axis of the blade body.
 7. The saw bladeof claim 1, wherein the saw blade further comprises a plurality of holesthrough the first inlay portion and the second inlay portion, theplurality of holes being arranged along a longitudinal axis of the bladebody.
 8. The saw blade of claim 7, wherein each hole in the plurality ofholes extends through the first inlay portion, the blade body, and thesecond inlay portion.
 9. The saw blade of claim 4, wherein the saw bladefurther comprises a plurality of holes through the first inlay portionand the second inlay portion, the plurality of holes extending along alongitudinal axis of the blade body.
 10. The saw blade of claim 9,wherein each hole in the plurality of holes extends through the firstinlay portion, the blade body, and the second inlay portion.
 11. A sawblade comprising a blade body having a top surface and a bottom surface,wherein the blade body is at least partially comprised of metal; acutting edge on a distal end of the blade body; and a coupling at aproximal end of the blade body configured to connect the blade body to ahandpiece adapted to oscillate the blade body, wherein the saw bladefurther comprises a first inlay portion and a second inlay portion,wherein: the first inlay portion covers a width of the top surface; thesecond inlay portion covers a width of the bottom surface; and each ofthe first and the second inlay portions comprises a composite material.12. The saw blade of claim 11, wherein the composite material isselected from the group consisting of a matrix material, a plasticmaterial, a filling material and a carbon fiber fabric material.
 13. Thesaw blade of claim 11, wherein the cutting edge comprises a connectorconfigured to mechanically interlock the cutting edge with the bladebody.
 14. The saw blade of claim 13, wherein the connector comprises aplurality of holes configured to mechanically interlock with the bladebody.
 15. The saw blade of claim 11, wherein the saw blade furthercomprises a plurality of holes through the first inlay portion, theblade body, and the second inlay portion, the plurality of holes beingarranged along a longitudinal axis of the blade body.
 16. A saw bladecomprising a blade body having a top portion and a bottom portion,wherein the blade body is at least partially comprised of a metal; acutting edge on a distal end of the blade body; and a coupling at aproximal end of the blade body configured to connect the blade body to ahandpiece adapted to oscillate the blade body, wherein the saw bladefurther comprises an inlay portion, wherein: the inlay portion issandwiched between the top portion and the bottom portion, and the inlayportion comprises a composite material.
 17. The saw blade of claim 17,wherein: the inlay portion has an upper surface and a lower surface, theupper surface of the inlay portion is covered by the top portion of theblade body, and the inlay portion is embedded in the bottom portion ofthe blade body.
 18. The saw blade of claim 18, wherein the saw bladefurther comprises a plurality of holes arranged along a longitudinalaxis of the blade body, wherein each hole in the plurality of holesextends through the top portion of the blade body, the inlay portion,and the bottom portion of the blade body.